Composite components with improved adhesion of polycarbonate/polyester compositions and polyurethane

Abstract

The present invention relates to a composite component comprising i) a support made of a thermoplastic composition comprising A) at least one polymer selected from the group consisting of aromatic polycarbonates, aromatic polyester carbonates, aromatic polyesters, and mixtures thereof, in an amount of from 20.0 to 85.0 parts by wt., based on the sum of components A and B; B) at least one rubber-modified vinyl (co)polymer in an amount of from 15.0 to 80.0 parts by wt., based on the sum of components A and B, and with a rubber content [R B ] of at least 25.0 parts by wt., based on component B; and C) at least one polymer additive in an amount of from 0 to 30.0 parts by wt., based on the sum of components A to C; and ii) at least one polyurethane layer, wherein the thermoplastic composition comprises a total rubber content [R], of at least 12 parts by wt., based on the sum of components A to C.

The invention claimed is: 
     
       1. A composite component comprising
 i) a support made of a thermoplastic composition comprising
 A) at least one polymer selected from the group consisting of aromatic polycarbonates, aromatic polyester carbonates, aromatic polyesters, and mixtures thereof, in an amount of from 30.0 to 64.9 parts by wt., based on the sum of components A and B; 
 B) at least one rubber-modified vinyl (co)polymer in an amount of from 35.1 to 70.0 parts by wt., based on the sum of components A and B, and with a rubber content [R B ] of at least 25.0 parts by wt., based on component B; and 
 C) at least one polymer additive in an amount of from 0 to 30.0 parts by wt., based on the sum of components A to C; and 
 
 ii) at least one polyurethane layer, 
 wherein the thermoplastic composition comprises a total rubber content [R], of at least 12 parts by wt., based on the sum of components A to C. 
 
     
     
       2. A composite component according to  claim 1 , wherein the thermoplastic composition of the support comprises
 A) from 40.0 to 64.9 parts by wt., based on the sum of components A and B, of at least one polymer selected from the group consisting of aromatic polycarbonates, aromatic polyester carbonates, aromatic polyesters, and mixtures thereof, and 
 B) from 35.1 to 60 parts by wt., based on the sum of components A and B, of at least one rubber-modified vinyl (co)polymer. 
 
     
     
       3. A composite component according to  claim 1 , wherein component A is a mixture of at least one aromatic polycarbonate and/or polyester carbonate and at least one aromatic polyester. 
     
     
       4. A composite component according to  claim 1 , wherein the polyurethane layer is produced by polymerization of a reactive polyurethane raw material mixture comprising
 I) at least one polyisocyanate component, 
 II) at least one polyfunctional H-active compound, and 
 III) optionally at least one polyurethane additive and/or process auxiliary substance 
 wherein the reactive polyurethane raw material mixture is in direct contact with the thermoplastic support which has been formed and solidified. 
 
     
     
       5. A composite component according to  claim 1 , wherein the polyurethane layer is produced by polymerization of a reactive polyurethane raw material mixture comprising
 I) at least one polyisocyanate component, 
 II) at least one polyfunctional H-active compound, and 
 III) optionally at least one polyurethane additive and/or process auxiliary substance 
 wherein the reactive polyurethane raw material mixture is in direct contact on a first side with the thermoplastic support which has been formed and solidified, and in direct contact on a second side with a decorative skin selected from the group consisting of polyvinyl chloride (PVC), thermoplastic polyolefins (TPO), thermoplastic polyurethane (TPU), and polyurethane spray skin. 
 
     
     
       6. A composite component according to  claim 4 , wherein the reactive polyurethane raw material mixture has a characteristic number of from greater than 80 to less than 125. 
     
     
       7. A composite component according to  claim 1 , wherein component C is selected from the group consisting of a flameproofing agent, a flameproofing synergist, a smoke-suppressing additive, an antidripping agent, an internal lubricant, an external lubricant, a mould release agents, a flowability auxiliary agent, an antistatic, a conductivity additive, a nucleating agent, a stabilizer, an antibacterially acting additive, an additive which improves scratch resistance, an IR absorbent, an optical brightener, a fluorescent additive, a filler, a reinforcing substance, a dyestuff, a pigment, an impact modifier which do not fall under the definition of component B, a Bronsted acid compound, and mixtures thereof. 
     
     
       8. A composite component according to  claim 1 , produced by a process which comprises
 i) injecting a melt of the thermoplastic composition into a first mould cavity and subsequently cooling; 
 ii) enlarging the cavity of the injection mould to thereby generate a gap; 
 iii) injecting into said gap between the thermoplastic component and the mould surface a reactive polyurethane raw material mixture comprising
 I) at least one polyisocyanate component, 
 II) at least one polyfunctional H-active compound, and 
 III) optionally at least one polyurethane additive and/or process auxiliary substance, 
 wherein the polyurethane raw material mixture polymerizes in direct contact with a surface of the thermoplastic support to give a compact polyurethane layer and/or to give a polyurethane foam layer; 
 
 iv) removing the composite component from the mould cavity, 
 wherein process steps (i) to (iv) follow one another directly. 
 
     
     
       9. A component of a track, air travel or motor vehicle comprising the composite component of  claim 1 . 
     
     
       10. A composite component comprising
 i) a support made of a thermoplastic composition comprising
 A) at least one polymer selected from the group consisting of aromatic polycarbonates, aromatic polyester carbonates, aromatic polyesters, and mixtures thereof in an amount of from 30.0 to 64.9 parts by wt., based on the sum of components A and B; 
 B) at least one rubber-modified vinyl (co)polymer in an amount of from 35.1 to 70.0 parts by wt., based on the sum of components A and B, and with a rubber content [R B ] of at least 25.0 parts by wt., based on component B; and 
 C) at least one polymer additive in an amount of from 0 to 30.0 parts by wt., based on the sum of components A to C; and 
 
 ii) at least one polyurethane layer, 
 wherein the thermoplastic composition has a quotient Q, which is calculated by the formula Q=[B]/[RB], of <2, where [B] is the content of component B based on the sum of components A and B, and [R B ] is the content of rubber based on component B, and 
 wherein the thermoplastic composition has a rubber content [R], which is calculated by the formula [R]=[R B ]·[B]/100, based on the sum of components A and B, of at least 12 parts by wt. 
 
     
     
       11. A composite component according to  claim 10 , wherein the quotient Q is less than 1.7. 
     
     
       12. A process for the production of a composite component according to  claim 1 ,
 which comprises 
 i) injecting a melt of the thermoplastic composition into a first mould cavity and subsequently cooling; 
 ii) enlarging the cavity of the injection mould to generate a gap; 
 iii) injecting into said gap between the thermoplastic component and the mould surface a reactive polyurethane raw material mixture comprising
 I) at least one polyisocyanate component, 
 II) at least one polyfunctional H-active compound, and 
 III) optionally at least one polyurethane additive and/or process auxiliary substance, 
 wherein the polyurethane raw material mixture polymerizes in direct contact with a surface of the thermoplastic support to give a compact polyurethane layer and/or to give a polyurethane foam layer; 
 
 iv) removing the composite component from the mould cavity; and 
 wherein process steps (i) to (iv) follow one another directly. 
 
     
     
       13. A process according to  claim 12 , wherein in process step (iii), the surface of the injection mould in contact with the thermoplastic composition is temperature-controlled at a temperature of from 50 to 95° C., and the surface of the injection mould in contact with the reactive polyurethane mixture is temperature-controlled at a temperature of from 50 to 160 ° C.